臺灣博碩士論文加值系統

隨著工業4.0的發展，在工業技術上都以智慧化工廠為核心目標，然而隨著國內逐漸走入少子高齡化社會，勞動人口大幅減少導致企業公司人事成本增加，而現今工具機廠大多依靠擁有加工經驗的技師來操作機台，使企業紛紛朝向智能化工具機發展來提升製程效率以及品質，可有效地解決人力短缺以及人為操作失誤所導致的品質控管問題。近年來在高精密的加工中，為了追求良好的加工品質與精度，使磨床的相關技術也逐漸受到重視，而磨削加工所使用的砂輪屬於不均質的刀具會於工具機主軸旋轉時產生過大的振動，此外在研磨過程中砂輪會有填塞與磨耗的問題，需要將砂輪進行修銳、修整以及抑制轉子的不平衡量，使砂輪加工前置的準備時間大幅降低，並且能夠延長轉子壽命與提升工件品質，而現今國內降低砂輪振動的方式大多利用軌道式平衡台進行靜態校正，但靜態校正後所造成的振動量已經無法符合高精度的工件品質，因此本研究開發了一套線上監控砂輪振動與動平衡校正系統，該系統主要分為三大部分，首先為線上監控主軸振動系統，將加速規與光電開關分別架設於砂輪頭座與主軸前方，搭配資料擷取卡取得當前主軸振動量與轉速值，並且即時顯示於控制器上；其二為估測砂輪主軸不平衡量系統，針對砂輪校正盤的三塊配重塊位置進行量測主軸振動，透過希爾伯特-黃轉換原理分解加速度訊號，並搭配光電開關擷取之轉速訊號，將兩感測器所量測的訊號進行相位時間差運算，取得磨床砂輪的不平衡量與角度位置；其三為動態平衡校正系統，基於影響係數法，估測砂輪原始之不平衡量與角度，並透過向量平衡機制與三角重心估測法可計算出三塊配重塊的等效質心與擺放位置，藉此抵銷砂輪不平衡量，使砂輪達到平衡效果。由實驗結果顯示，經由傳統靜平衡校正後的砂輪，旋轉的振動位移量約為0.4~0.6μm，而透過本研究的動平衡校正系統，可以降低至0.1~0.2μm，大幅減少28.57~58.33%的砂輪旋轉振動，同時也達到國際動平衡標準ISO-1940的最高G0.4等級。將上述的系統與平面磨床進行整合，使本研究開發的線上監控砂輪振動與動平衡校正系統能夠縮減加工前置作業的準備時間，並且延長主軸壽命與提升工件的表面粗糙度品質，達到智慧化磨床之目的。

With the development of Industry 4.0, smart factories are the core goal of industrial technology. However, with the domestic gradually into the low birthrate and aging society, the drastic reduction in the labor force has increased personnel costs for companies. Nowadays, machine tool factories mostly rely on technicians with processing experience to operate the machines. Companies are moving towards intelligent machine tools to improve process efficiency and quality, effectively solving the shortage of workforce and control quality caused by human errors. To pursue good processing quality and precision in high-precision processing, the related technology of grinders has gradually attracted attention. Because the grinding wheel is a non-homogeneous tool, it will produce excessive vibration when the spindle rotates. In addition, there will be filling and wear problems in the process, which needs to be dressed to eliminate rotor unbalance. In the end, it can shorten the preparation time before processing, extend the rotor's life, and improve the quality of the workpiece. Nowadays, most domestic methods to reduce the vibration of the grinding wheel uses the track-type balance table for static correction. Still, it hasn't met the high-precision workpiece quality, so this research has developed an Online Monitoring Vibration and Dynamic Balance Correction System of Grinding Wheel. The system consists of three major parts: online monitoring of the spindle, estimation of the unbalance of the grinding wheel, and dynamic balance correction. The first is to monitor the spindle vibration online. The accelerometer and photoelectric sensor are installed above the grinder's head and the front of the spindle. The vibration and speed of the spindle can be displayed in real-time on the controller through a data acquisition device. The second is to estimate the unbalance of the grinding wheel spindle, measure the spindle vibration for different positions, and filter the signals that are not current speed through the Hilbert-Huang Transform principle. Perform phase time difference calculation on the signals measured by the two sensors to obtain the unbalance and angle of the grinding wheel. The third is dynamic balance correction, which estimates the original unbalance and angle of the grinding wheel based on the influence coefficient method. Then the position of the three correction masses can be obtained by the vector balance mechanism and triangle center of gravity estimation method. Finally, it eliminates the unbalance of the grinding wheel and achieves a balancing effect. The experimental results show that the rotational vibration displacement of the grinding wheel after the traditional static balance correction is about 0.4~0.6μm, and through the dynamic balance correction system of this research, it can reach 0.1~0.2μm. Significantly reduce 28.57~58.33% of the grinding wheel rotation vibration and achieve the highest G0.4 grade of the international dynamic balance standard ISO-1940. Integrating the system with the surface grinder can reduce the time for pre-processing, extend the life of the spindle and improve the surface roughness quality of the workpiece, achieving the purpose of an intelligent grinder.

摘要...i
Abstract...ii
誌謝...iv
目錄...v
表目錄...viii
圖目錄...ix
符號說明...xii
第 一 章 緒論...1
1.1 研究背景與動機...1
1.2 研究目的...2
1.3 論文架構...2
第 二 章 文獻回顧...3
2.1 動平衡校正方法國內外相關研究...3
第 三 章 研究架構與方法...12
3.1 研究架構與流程...12
3.2 硬體及系統架構...13
3.2.1 實驗機台介紹...13
3.2.2 動平衡實驗之硬體設備...13
3.3 轉子平衡方法與原理...15
3.3.1 影響係數法...15
3.3.2 僅量相角法...17
3.3.3 三配平塊移動平衡法...19
3.3.4 微調平衡原理...20
3.4 主軸旋轉振動訊號擷取系統...21
3.4.1 砂輪主軸旋轉振動訊號...22
3.4.2 砂輪旋轉週期訊號...23
3.5 砂輪主軸振動數據處理...24
3.5.1 希爾伯特-黃轉換...24
3.5.2 核心尋峰演算法...30
3.5.3 高斯常態分佈...31
3.6 砂輪動平衡校正系統...32
3.6.1 動平衡標準規範ISO-1940...32
3.6.2 砂輪配重平衡校正...34
第 四 章 實驗結果...37
4.1 靜平衡校正誤差實驗...37
4.1.1 砂輪靜平衡建置...37
4.1.2 振動量測系統建置...38
4.1.3 各軸向振動量測實驗...39
4.2 砂輪動平衡校正系統建置...40
4.2.1 影響係數法...40
4.2.2 僅量相角法...44
4.2.3 三配平塊移動平衡法...46
4.2.4 不同校正方法的結果比較...49
4.3 動平衡校正模型估測誤差實驗...49
4.3.1 在2400rpm轉速下的動平衡校正結果...50
4.3.2 在2700rpm轉速下的動平衡校正結果...52
4.3.3 在3000rpm轉速下的動平衡校正結果...55
4.3.4 各轉速的動平衡校正結果...57
4.4 動平衡校正系統的精度誤差實驗...58
4.4.1 砂輪主軸轉速的精度誤差實驗...58
4.4.2 砂輪主軸振動的精度誤差實驗...59
第 五 章 結論與未來展望...64
參考文獻...65
Extended Abstract...67
1 . Introduction...69
2 . Experiment & Methodology...70
2.1 System setup...70
2.2 Experimental parameters...70
2.3 Analytical model...70
2.3.1 Influence coefficient method...71
2.3.2 Balancing with phase only...72
2.3.3 Three correction masses moving balance method...73
2.3.4 Fine-tuning balance principle...74
2.3.5 Dynamic balance correction model...75
2.4 Signal processing...76
2.4.1 Vibration signal mode decomposition...76
2.4.2 Core peak finding algorithm...81
2.4.3 International dynamic balance standard...82
3 . Results and discussions...84
3.1 Triaxial grinding wheel vibration test...84
3.2 Dynamic correction results of various estimated unbalance...84
3.2.1 Influence coefficient method...85
3.2.2 Balancing with phase only...87
3.2.3 Three correction masses moving balance method...89
3.2.4 Correction results of different estimation methods...91
3.3 Experiment of estimation error of dynamic balance correction model...91
3.3.1 Dynamic balance correction results at 2400 rpm...91
3.3.2 Dynamic balance correction results at 2700 rpm...93
3.3.3 Dynamic balance correction results at 3000 rpm...94
3.3.4 Dynamic balance correction results for each speed...96
4 . Conclusion...97

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